RL Facility Representative Program February 25, 2000
Surveillance Guide CPS 8.1 Revision 1
Hoisting and Rigging Page 1 of 12
HOISTING AND RIGGING
1.0 Objective
The objective of this surveillance is to examine hoisting and rigging operations to ensure that safe equipment and work practices are being used. The surveillance includes verification that hoisting and rigging work is performed in accordance with DOE requirements and best practices.
2.0 References
2.1 DOE O 440.1A, Worker Protection Management For Doe Federal And Contractor Employees
2.2 DOE-RL-92-36, Hanford Site Hoisting and Rigging Manual
NOTE
The DOE Hoisting and Rigging Manual should be used as the primary reference for this surveillance.
1
3.0 Requirements Implemented
This surveillance is conducted to implement the RL Functions, Responsibilities, and Authorities Manual (FRAM) item No. 2504.
4.0 Surveillance Activities
During this surveillance, the Facility Representative (FR) may evaluate one or more aspects of a facility's hoisting and rigging program. The surveillance may involve field observations of a lift, field review of equipment, a program evaluation, or a review of hoisting and rigging records. Choose one or more of the sections identified below to evaluate, as appropriate. After each question, the Hoisting and Rigging manual reference is included in brackets. Prior to initiating a surveillance, it is highly recommended that the FR review the complete sections of DOE-RL-92-36, "Hanford Site Hoisting and Rigging Manual," to obtain additional information and review all detailed requirements imposed on the activity or program. This manual can be found at http://www.hanford.gov/docs/rl9236/rl9236tc.htm.
Surveillance Guideline
HOISTING AND RIGGING
Surveillance No.:
Facility:
Date Completed:
HANFORD SITE HOISTING AND RIGGING MANUAL SECTIONS
Section 2, Responsibilities
Yes No N/A
______1. Is the crane's rated capacity marked on each side of the crane?
______2. Is a supervisor or manager responsible for H&R operations at this facility? [2.2.1]
______3. Is a supervisor or manager assigned responsibility for inspection, maintenance, and repair of H&R equipment and components? [2.2.2]
______4. Do responsible inspectors, maintenance, and test personnel have access to adequate information? Such information would include: operating instructions; maintenance and repair information (instructions); manufacturer's recommendations concerning lubrication; wiring diagrams. [2.2.2.c]
______5. Is a Person-In-Charge (PIC) assigned for each critical lift? [2.2.3]
______6. Is a designated leader appointed to all H&R activities, including critical and non-critical ordinary lifts, that require more than one person? [2.2.4]
______7. Does a responsible safety organization monitor your H&R operations to ensure that they are performed safely? [2.3.1]
______8. Do all personnel involved in a hoisting and rigging activity have a clear understanding of their duties and responsibilities? [2.2.3 through 2.2.6]
______9. Other
Section 3, Critical Lifts
Yes No N/A
______1. Do critical lift procedures contain adequate and appropriate information? [3.4.1]
______2. Are critical lift procedures (and any revision) reviewed and approved by the author, responsible manager, PIC, and the Safety Organization? [3.4.2/3]
______3. Are pre-lift meeting(s) held to review procedures and resolve questions before making critical lifts? [3.5]
______4. Are pre-lift meetings documented? [3.6(2)]
______5. Is appropriate critical lift documentation maintained for one year following the lift? [3.6]
______6. Other
Section 4, Personnel Qualifications And Training Requirements
Yes No N/A
______1. Does the contractor have a documented training and qualification program for hoisting and rigging activities? [4.3]
______2. Does the qualification program include 1) classroom or computer based training, 2) written tests, 3) On-the-job training (OJT), and 4) On-the-job evaluations (OJE). [4.3]
______3. Are personnel requalified on a frequency of 36 months or less? [4.3.4]
______4. Do written, oral, and performance tests have established pass/fail criteria? [4.6]
______5. Are qualified personnel issued qualification cards with the appropriate information? [4.7.2]
______6. Other.
Section 5, Hooks
Yes No N/A
______1. Are new and repaired hooks inspected to ensure compliance with applicable provisions of ASME B30.10, Hooks. [5.4.1.1]
______2. Does the operator or other designated person visually inspect the hook daily, before use? [5.4.1.2]
______3. Are hooks periodically inspected by a qualified inspector on the proper frequency (depending on service classification)? Are documented records available to verify periodic hook inspections? [5.4.3]
______4. Do hook inspections look at 1) distortion, 2) wear, 3) cracks, nicks, or gouges, 4) latch engagement, and 5) hook attachment? [5.4.4]
______5. Are hooks with excessive wear or deformation removed from service? [5.4.5]
______6. Do existing crane/hoist hooks rated greater or equal to 10 tons and assigned to heavy or severe service receive an NDT by a qualified inspector at the following intervals:
a. Heavy service --annually
b. Severe service--semi-annually (every 6 months)
Note: Hooks in normal service do not routinely require NDT. [5.5.2]
______7. Other.
Hook Service Classificationsservice, normal--service that involves operating at less than 85% of rated load except for isolated instances
service, heavy--service that involves operating at 85% to 100% of rated load as a regular specified procedure
service, severe--heavy service coupled with abnormal operating conditions
Section 6, Forklift Trucks
Yes No N/A
______1. Does management classify and post hazardous locations before a forklift truck is assigned to work in the area? [6.2.1.a]
______2. Does management ensure forklift operators are properly trained and qualified? [6.2.1.d]
______3. Has management designated an area for battery charging of electric forklifts? [6.2.1.e]
______4. Are personnel assigned and trained to change out LP-gas containers for LP-gas powered forklifts? [6.2.1.f]
______5. For forklift trucks assigned to this facility, are frequent inspection (pre-use) inspection instructions readily available to the operator? [6.2.2.2.b]
______6. Are forklift truck operators at this facility familiar with and do they accomplish frequent (pre-use) inspections? [6.2.3]
______7. Examine forklift trucks at this facility to determine if the manufacturer's plates, tags, labels, and decals are in legible condition. [6.2.2.d and 6.3.1]
______8. Do forklift attachments (excluding fork extensions) have nameplates attached with the appropriate information? [6.3.3]
______9. Are front-end attachments used with any forklift truck(s) at this facility? If so, is the truck(s) marked to identify the attachment(s), the approximate weight of the truck and attachment combination, and the capacity of the truck with the attachment(s)? [6.4.1]
______10. Is prior written approval obtained from the manufacturer prior to making modifications or additions that affect forklift capacity or safe operation? Are capacity operation and maintenance instruction plates, tags, or decals changed accordingly? [6.4.2]
______11. Do management and forklift operators understand what "free rigging" is? Do they understand the process that is required to utilize "free rigging"? [6.4.3]
______12. Do forklift operators understand the basis for forklift capacity and the need to "de-rate" a forklift for large or unusually configured loads? [6.12.c and d]
______13. Other
Section 7, Shop Cranes
Yes No N/A
______1. Are operating instructions readily available for shop cranes? [7.2]
______2. Does each shop crane have the rated capacity for each specified boom and leg position marked in a prominent location? [7.5.1]
______3. Is the manufacturer's warning statement affixed to the shop crane? [7.5.3]
______4. Is maintenance performed for each shop crane in accordance with the manufacturer's instructions? [7.7]
______5. Other
Section 8, Wire Rope
Yes No N/A
______1. Identify cranes or hoists at this facility that use rotation-resistant wire rope. Are special installation, inspection, and maintenance procedures readily available for rotation-resistant wire rope? [8.2.2]
______2. Confirm that independent wire rope core (IWRC) is used on all mobile cranes and any other hoist or crane that could operate at temperatures in excess of 180F. [8.2.3]
______3. Review wire rope inspection procedures used at the facility. Do the procedures provide clear instructions/acceptance criteria that are in accordance with DOE-RL-92-36? [8.3 and 8.4]
______4. Are inspection records available for wire ropes on H&R equipment at this facility? [8.3]
______5. If wire rope is stored at this facility, is it adequately protected? [8.5.2]
______6. Other.
Section 9, Slings
Yes No N/A
______1. Are alloy steel chain slings properly labeled? [9.2.2.3]
______2. Does the chain sling inspection program at this facility meet the requirements of DOE-RL-92-36? [9.2.2.6]
______3. Are periodic inspections on alloy steel chain slings documented? [9.2.2.6.2]
______4. Have wire rope slings at this facility been proof tested? [9.2.3.3]
______5. Are wire rope slings labeled with a tag or other identification method that provides: manufacturer's name, rated load, load test date, periodic inspection due date? [9.2.3.4]
______6. Is there evidence that personnel who use wire rope slings understand and practice frequent (pre-use) inspection? [9.2.3.8.1]
______7. Review the periodic inspection program employed at this facility for wire rope slings. Is it in accordance with DOE-RL-92-36? [9.2.3.8.2]
______8. Are wire rope slings immediately removed from service if inspections identify adverse conditions? [9.2.3.8.3]
______9. Determine by field inspection if synthetic web slings are labeled to state the following:
a. Manufacturer's name or trademark
b. Manufacturer's code or stock number
c. Rated loads for the types of hitches used
d. Type of synthetic web material
e. An additional tag, sticker, or other identifier to indicate when the next periodic inspection is required.
f. Synthetic web slings used for critical lifts shall have a tag or other identifier to indicate that a proof test has been performed.
[9.2.5.1.4]
______10. Is there evidence that a "before use" inspection is done on synthetic web slings at this facility? [9.2.5.6.2]
______11. Is there evidence of an acceptable periodic inspection program for synthetic web slings at this facility? (The periodic inspection shall be made at least annually and shall be documented.) [9.2.5.6.3]
______12. Other
Section 10, Rigging Hardware
Yes No N/A
______1. Do shackles and pins have appropriate manufacturing markings? [10.2.2]
______2. Are shackles and rings properly inspected before each use? [10.2.3]
______3. Are shackles used for critical-lift service proof load tested to two times the safe working load? [10.2.5]
______4. Are turnbuckles used for critical-lift service initially proof tested at two times the rated capacity? Do tested turnbuckles have a tag or other marking to indicate that proof testing has been done? [10.5.3]
______5. Other.
Section 11, Below-The-Hook Lifting Devices
Yes No N/A
______1. Inspect below-the-hook lifting devices to determine if they are properly tagged/marked. 11.4
______2. Are modifications to below-the-hook lifting devices properly analyzed and documented? [11.5]
______3. Is there an established program, including records, for periodic inspection of below-the-hook lifting devices? [11.7.3 and 11.7.4]
______4. Have below-the-hook lifting devices at this facility been subjected to a rated load test? Is documentation available to verify rated load tests? [11.9.1.4 and/or 11.9.1.5]
______5. Are maintenance history files maintained for below-the-hook lifting devices? [11.10]
______6. Other.
Section 12, Hoists, Jib Cranes, And Monorail Systems
Yes No N/A
______1. Is the operation of hoists, jib cranes, and monorail systems at this facility limited to qualified personnel? [12.2]
______2. Are hoists provided with the proper identification markings ? [12.8.1]
______3. Are hoists provided with the proper identification warning labels, if equivalent training has not been conveyed to and understood by the users? [12.8.2]
______4. Are hand signals used for controlling hoists at this facility? If so, are hand signal charts posted conspicuously at the job site(s)? [12.8.3]
______5. The absence of a hook throat latch is not indiscriminately allowed. Review operating conditions for any hoist hooks at this facility which operate without a throat latch. Should throat latches be installed? [12.8.9]
______6. For pendant controls:
a. Are the pushbutton stations supported so that the electrical conductors are protected from strain?
b. Do pushbuttons spring return to the off position when pressure is released by the operator?
c. To the extent possible, is each control clearly marked to indicate the direction of resultant motion?
[12.10.2]
______7. Are electrical supplies for permanently installed hoists and monorail systems shall be controlled by a lockable switch or circuit breaker located on a fixed structure, accessible from the floor. [12.10.3]
______8. Is there evidence of a Frequent/Periodic Inspection Program for hoists at this facility? [12.12 and Tables 12-1, 12-2, 12-3]
______9. Are there hoists, jib cranes, or monorail systems at this facility that are considered standby equipment (idle for 1 month or more)? If so, are they inspected (equal to Frequent Inspection) before being placed in service? Does equipment used for standby service receive a Periodic Inspection and operational test no less than annually. [12.12.6]
______10. For hoists, jib cranes and monorail systems at this facility, is there a Preventive Maintenance program? Is this program based on the manufacturer's, or a qualified person's, recommendations? [12.16.1]
______11. Are load tests conducted in accordance with written step-by-step procedures? [12.17.5]
______12. Other
Section 13, Overhead And Gantry Cranes
Yes No N/A
______1. Is the operation of overhead and gantry cranes at this facility limited to properly qualified personnel? [13.2.1]
______2. Has the facility established an OJE program to verify the qualifications of all personnel (including outside organizations) that are allowed to use a facility crane? [13.2.1]
______3. Inspect marking of overhead and gantry cranes at this facility:
a. Is the rated load of the crane marked on each side of the crane?
b. If the crane has more than one hoisting unit, does each hoist have its rated load marked on it or its load block?
c. Load blocks should be painted to contrast with the bridge and trolley to facilitate quick visual identification. Do blocks at this facility follow this recommendation?
d. Are marking on the bridge, trolley, and load block legible from the ground floor?
[13.7.1]
______4. Are hand signals used for overhead or gantry cranes at this facility? If so, are hand signal charts posted conspicuously at the job site(s)? [13.7.2]
______5. Is a means of egress from cab-operated cranes provided to permit departure under emergency conditions? [13.7.3]
______6. For cab-operated cranes at this facility, is there a 10BC portable fire extinguisher, minimum, installed in the cab and maintained in a serviceable condition? [13.7.5]
______7. Inspect pendant control stations on overhead and gantry cranes.
a. Are the pushbutton stations supported so that the electrical conductors are protected from strain?
b. To the extent possible, is each control clearly marked to indicate the direction of resultant motion?
c. Do push buttons spring-return to the "off" position when pressure is released by the operator?